U.S. patent application number 14/961486 was filed with the patent office on 2017-06-08 for product packaging with coc-coc sealing interface.
The applicant listed for this patent is Bemis Company, Inc.. Invention is credited to Michael Drew Priscal, Arthya Puguh.
Application Number | 20170158400 14/961486 |
Document ID | / |
Family ID | 58799675 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170158400 |
Kind Code |
A1 |
Priscal; Michael Drew ; et
al. |
June 8, 2017 |
PRODUCT PACKAGING WITH COC-COC SEALING INTERFACE
Abstract
A package includes a base component having a product contacting
layer including at least 50% by weight of a cyclic olefin
copolymer, and a lidding component having a product contacting
layer including at least 50% by weight of a cyclic olefin
copolymer. The product contacting layer of the base component is
sealed to the product contacting layer of the lidding component
such that a cavity is formed.
Inventors: |
Priscal; Michael Drew;
(Neenah, WI) ; Puguh; Arthya; (Neenah,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bemis Company, Inc. |
Neenah |
WI |
US |
|
|
Family ID: |
58799675 |
Appl. No.: |
14/961486 |
Filed: |
December 7, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/304 20130101;
B32B 27/34 20130101; B32B 15/20 20130101; B32B 15/09 20130101; B32B
2255/10 20130101; B32B 2255/205 20130101; B32B 27/327 20130101;
B32B 2307/31 20130101; B32B 2307/518 20130101; B32B 2307/702
20130101; B32B 2307/7265 20130101; B32B 2250/40 20130101; B32B
27/325 20130101; B32B 27/18 20130101; B32B 29/002 20130101; B32B
2255/06 20130101; B32B 27/302 20130101; B32B 27/32 20130101; B32B
27/06 20130101; B32B 2307/738 20130101; B32B 15/088 20130101; B32B
7/12 20130101; B32B 2307/732 20130101; B32B 2307/714 20130101; B32B
2307/7248 20130101; B32B 2307/7246 20130101; B32B 27/36 20130101;
B32B 27/306 20130101; B32B 2307/50 20130101; B32B 2307/7242
20130101; B32B 2307/7244 20130101; B32B 2553/00 20130101; B32B
2439/80 20130101; B32B 15/085 20130101; B32B 15/12 20130101; B32B
2307/406 20130101; B32B 2307/412 20130101; B32B 27/08 20130101;
B32B 3/28 20130101; B32B 27/10 20130101; B65D 75/327 20130101; B32B
2270/00 20130101 |
International
Class: |
B65D 65/40 20060101
B65D065/40; B32B 27/32 20060101 B32B027/32; B32B 27/08 20060101
B32B027/08; B65D 75/36 20060101 B65D075/36 |
Claims
1. A package comprising: a base component comprising a product
contacting layer comprising at least 50% by weight of a cyclic
olefin copolymer; and a lidding component comprising a product
contacting layer comprising at least 50% by weight of a cyclic
olefin copolymer; wherein the product contacting layer of the base
component is sealed to the product contacting layer of the lidding
component such that a cavity is formed.
2. The package of claim 1, wherein the base component is a
multilayer thermoplastic film that comprises: the product
contacting layer comprising at least 50% by weight of the cyclic
olefin copolymer, a first interior layer, a core layer, a second
interior layer, and an exterior layer comprising at least one
material selected from the group consisting of cyclic olefin
copolymer (COC), polypropylene (PP), high impact polystyrene
(HIPS), general purpose polystyrene (GPPS), styrene block copolymer
(SBC), polyethylene terephthalate (PET), oriented polyethylene
terephthalate (OPET), amorphous polyethylene terephthalate (APET),
glycol-modified polyethylene terephthalate (PETG), biaxially
oriented nylon (BON), and polylactic acid (PLA).
3. The package of claim 2, wherein the first interior layer and the
second interior layer each comprise at least one of a high density
polyethylene nucleation additive or a hydrocarbon resin.
4. The package of claim 2, wherein the first interior layer and the
second interior layer each comprise a bimodal high density
polyethylene having a distribution of a low molecular weight region
and a high molecular weight region.
5. The package of claim 2, wherein the core layer comprises an
ethylene vinyl acetate copolymer.
6. The package of claim 2, wherein the exterior layer of the base
component comprises at least 50% by weight of a cyclic olefin
copolymer.
7. The package of claim 1, wherein the cyclic olefin copolymer of
at least one of the base component or the lidding component
comprises norbornene and ethylene monomers.
8. The package of claim 1, wherein the lidding component comprises:
a barrier layer; and the product contacting layer comprising at
least 50% by weight of a cyclic olefin copolymer.
9. The package of claim 8, wherein the lidding component further
comprises an exterior layer disposed over the barrier layer that
comprises at least one of paper, biaxially oriented nylon,
biaxially oriented polypropylene, or oriented polyethylene
terephthalate.
10. The package of claim 14, wherein the lidding component further
comprises an interior layer disposed between the exterior layer and
the barrier layer that comprises at least one of polyethylene and
an adhesive.
11. The package of claim 1, wherein the seal between the product
contacting layer of the base component and the product contacting
layer of the lidding component has a seal strength of at least 800
grams force per inch.
12. A lidding component for a package comprising: a barrier layer;
and a product contacting layer comprising at least 50% by weight of
a cyclic olefin copolymer, wherein the product contacting layer is
configured to seal to a product contacting layer of a base
component.
13. The lidding component of claim 19, further comprising an
exterior layer disposed over the barrier layer that comprises at
least one of paper, biaxially oriented nylon, biaxially oriented
polypropylene, or oriented polyethylene terephthalate.
14. The lidding component of claim 13, further comprising an
interior layer disposed between the exterior layer and the barrier
layer that comprises at least one of polyethylene and an
adhesive.
15. A method of forming a package, comprising: sealing a product
contacting layer comprising at least 50% by weight of a cyclic
olefin copolymer of a base component to a product contacting layer
comprising at least 50% by weight of a cyclic olefin copolymer of a
lidding component to form a cavity.
16. The method of claim 15, further comprising forming the base
component by a blown coextrusion process and forming the lidding
component by a lamination process.
17. The method of claim 15, wherein the sealing is a heat sealing
process.
18. The method of claim 15, wherein the base component is a
multilayer thermoplastic film that comprises: a product contacting
layer comprising at least 50% by weight of the cyclic olefin
copolymer, a first interior layer, a core layer, a second interior
layer, and an exterior layer comprising at least one material
selected from the group consisting of cyclic olefin copolymer
(COC), polypropylene (PP), high impact polystyrene (HIPS), general
purpose polystyrene (GPPS), styrene block copolymer (SBC),
polyethylene terephthalate (PET), oriented polyethylene
terephthalate (OPET), amorphous polyethylene terephthalate (APET),
glycol-modified polyethylene terephthalate (PETG), biaxially
oriented nylon (BON), and polylactic acid (PLA).
19. The method of claim 18, wherein the exterior layer of the base
component comprises at least 50% by weight of a cyclic olefin
copolymer.
20. The method of claim 15, wherein the lidding component
comprises: a barrier layer; and the product contacting layer
comprising at least 50% by weight of a cyclic olefin copolymer.
21. The method of claim 20, wherein the lidding component further
comprises an exterior layer disposed over the barrier layer that
comprises at least one of paper, biaxially oriented nylon,
biaxially oriented polypropylene, or oriented polyethylene
terephthalate.
22. The method of claim 15, wherein the lidding component further
comprises an interior layer disposed between the exterior layer and
the barrier layer that comprises at least one of polyethylene and
an adhesive.
Description
BACKGROUND
[0001] The present application relates generally to packaging
materials and configurations for commercial packaging operations.
According to one particular embodiment, the packaging may be
provided in the form of tray and lid packaging, container and lid
packaging, blister packaging, or "push-through" packaging.
[0002] Blister packaging is employed widely for commercial
packaging of food products, personal care products, and human
health products such as pharmaceuticals, and medical devices or
precision instruments. The use of this type of packaging has become
widespread mainly due to the ability to incorporate suitable
moisture, dust, ultraviolet (UV), and/or gas barriers into the
packages when such properties are desired for maintaining the
integrity or efficacy of the product contained therein. For
example, blister packaging is extensively used in the
pharmaceutical industry for packaging of medicaments or the like in
capsule, lozenge, or pill form because the integrity of the
medicament can be maintained through the proper selection of
materials used to form the packages.
[0003] For preparing blister packages or push-through packages,
generally a thermoplastic film is first processed by vacuum forming
or pneumatic forming so as to form blisters or cavities thereon,
namely portions having a predetermined contour that generally
corresponds to the size and shape of each specific product to be
received or contained therein. After the so-blistered film has been
solidified, each blister is charged with the product to be packaged
and a second or lidding film is then covered over each blister and
sealed to the first film. The second lidding film is often a
laminate material which can be ruptured by a simple finger-rupture
or peeled off from the first film to allow access to a packaged
item. Conventional materials used for forming the blistered film
have included transparent plastics such as polyvinylchloride (PVC),
polyvinylidene chloride (PVdC), and polychlorotrifluoroethylene
(PCTFE), commonly referred to as ACLAR.RTM. (Honeywell/Allied
Signal).
[0004] Packaging for pharmaceuticals or other moisture-sensitive
articles desirably exhibits not only low moisture permeability, but
also other properties such as chemical inertness, clarity,
rigidity, and/or uniform thickness. Conventional materials for such
blister packaging generally suffer from certain shortcomings,
however. For example, the use of polyvinylchloride (PVC) and
polyvinylidene chloride (PVdC) have been shown to have poor and/or
insufficient moisture-proofing properties required by the
pharmaceutical industry. While ACLAR.RTM. exhibits relatively low
moisture vapor transmission, its use in blister packaging is
relatively costly as compared to alternative materials.
Additionally, in some cases, undesirable migration of chemicals or
other components of the product, such as pharmacological active
agents or excipients, between the product and the packaging
materials (e.g., film, film layer, etc.) may occur (i.e., scalping
or leaching).
[0005] There is therefore a need in the art for improved packaging
materials and configurations that may provide sufficient moisture
vapor barrier, anti-scalping, and chemical inertness properties and
that is aesthetically pleasing enough to present the products
contained therein while being cost effective to manufacture.
SUMMARY
[0006] One embodiment relates to a package including: a base
component comprising product contacting layer comprising at least
50% by weight of a cyclic olefin copolymer, and a lidding component
comprising product contacting layer comprising at least 50% by
weight of a cyclic olefin copolymer. The product contacting layer
of the base component is sealed to the product contacting layer of
the lidding component such that a cavity is formed.
[0007] The base component may be a multilayer thermoplastic film.
The multilayer thermoplastic film may include: the product
contacting layer comprising at least 50% by weight of the cyclic
olefin copolymer, a first interior layer, a core layer, a second
interior layer, and an exterior layer. The exterior layer may
include at least one of cyclic olefin copolymer (COC),
polypropylene (PP), high impact polystyrene (HIPS), general purpose
polystyrene (GPPS), styrene block copolymer (SBC), polyethylene
terephthalate (PET), oriented polyethylene terephthalate (OPET),
amorphous polyethylene terephthalate (APET), glycol-modified
polyethylene terephthalate (PETG), biaxially oriented nylon (BON),
or polylactic acid (PLA). The first interior layer and the second
interior layer may each comprise a high density polyethylene
nucleation additive, and may each further include a hydrocarbon
resin. The first interior layer and the second interior layer each
may include a bimodal high density polyethylene having a
distribution of a low molecular weight region and a high molecular
weight region. The first interior layer and the second interior
layer each may be in direct contact with an exterior layer. The
core layer may include an ethylene vinyl acetate copolymer, and may
be in direct contact with the first interior layer and the second
interior layer. The exterior layer of the base component may
include at least 50% by weight of a cyclic olefin copolymer.
[0008] The lidding component of the package may include: an
optional exterior layer; a barrier layer; and the product
contacting layer comprising at least 90% by weight of a cyclic
olefin copolymer. The barrier layer may be a foil layer. The
exterior layer may be at least one of paper, biaxially oriented
nylon, biaxially oriented polypropylene, or oriented polyethylene
terephthalate. The lidding component may further include an
interior layer disposed between the exterior layer and the barrier
layer. The interior layer may include at least one of polyethylene
and an adhesive.
[0009] The cyclic olefin copolymer of at least one of the base
component or the lidding component may include norbornene and
ethylene monomers. The seal between the product contacting layer of
the base component and the product contacting layer of the lidding
component may have a seal strength of at least 800 grams force per
inch.
[0010] A second embodiment relates to a lidding component for a
package, the lidding component including: an optional exterior
layer, a barrier layer, and a product contacting layer comprising
at least 50% by weight of a cyclic olefin copolymer. The product
contacting layer being configured to seal to a product contacting
layer of a base component. The barrier layer may be a foil layer.
The exterior layer may be at least one of paper, biaxially oriented
nylon, biaxially oriented polypropylene, or oriented polyethylene
terephthalate. The lidding component may further include an
interior layer disposed between the exterior layer and the barrier
layer. The interior layer may include at least one of polyethylene
and an adhesive.
[0011] A third embodiment relates to a method of forming a package.
The method includes: sealing a product contacting layer comprising
at least 50% by weight of a cyclic olefin copolymer of a base
component to a product contacting layer comprising at least 50% by
weight of a cyclic olefin copolymer of a lidding component to form
a cavity. The method may further include forming the base component
by a blown coextrusion process. The base component may be any of
the base components described above. The method may also further
include forming the lidding component by lamination process. The
lidding component may be any of the lidding components described
above. The sealing may be a heat sealing process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] References are made to the accompanying drawings that form a
part of this disclosure, and which illustrate the embodiments in
which the systems and methods described in this specification can
be practiced.
[0013] FIG. 1 is a schematic view of a package according to a
non-exclusive and non-limiting exemplary embodiment, shown in the
form of a blister package.
[0014] FIG. 2 is a cross-sectional view of the package of FIG. 1
taken along line A-A.
[0015] FIG. 3 is a cross-sectional view of a portion of a package
according to another exemplary embodiment.
[0016] FIG. 4 is a cross-sectional view of a portion of a package
according to another exemplary embodiment.
[0017] FIG. 5 is a cross-sectional view of a portion of a package
according to another exemplary embodiment.
[0018] FIG. 6 is a cross-sectional view of a portion of a package
according to another exemplary embodiment.
DETAILED DESCRIPTION
[0019] Embodiments described and depicted herein relate generally
to packages formed from a base component (e.g., a blister portion,
tray portion, or container portion in which one or more products to
be packaged are contained or housed) and a lidding component (e.g.,
a cover, film, or lid coupled to the base component for sealing or
closing the product(s) within the base component). The base
component and the lidding component may be separate components
before they are sealed together. It should be understood, however,
that the concepts described herein may also apply to other types of
packaging, which have a plurality of components to be joined or
sealed together in manners similar to those described herein, and
such other packaging types are intended to fall within the scope of
the present disclosure.
[0020] According to an exemplary embodiment, the base component and
the lidding component are independently formed from multilayer
polymeric materials, and the layers of the base component and
lidding component in facing contact with each other (i.e., the
sealing surfaces of each) include a cyclic olefin copolymer (COC)
material. Such facing layers may also be referred to herein as a
product contact layer or a product contacting layer, since the
contained product(s) may contact, directly or indirectly, all or a
portion of such layer when the product(s) are contained within the
package.
[0021] A representative blister package 10 as described herein is
shown in FIGS. 1 and 2 according to one non-exclusive and
non-limiting exemplary embodiment. Blister package 10 includes a
thermoformed base component 12 and a lidding component 11. The base
component 12 and the lidding component 11 are sealed together to
form sealed flange regions surrounding cavities 13 (e.g.,
compartments, storage areas, openings, chambers, channels, etc.).
The cavities 13 define individual areas or regions for receiving
and containing one or more products 15, such as a tablet, patch, or
cartridge. As will be appreciated by those reviewing the present
disclosure, any of a wide variety of product types may be contained
within the blister package 10.
[0022] According to one particular embodiment, the product may be a
replacement cartridge for an electronic cigarette system.
Alternative packages that may be formed using the base component
and the lidding component described herein include tray and lid
packages and container and lid packages.
Base Component
[0023] As used throughout this disclosure, the term "base
component" refers to multilayer thermoplastic film or a roll of
multilayer thermoplastic film both of which may be thermoformed,
partially thermoformed, or not thermoformed at all. The multilayer
thermoplastic film may include layers that do not include a
thermoplastic materials, such as metal foils or paper. In one
exemplary embodiment, the sequence of layers in the multilayer
thermoplastic film of the base component is palindromic. As used
throughout this application, the term "palindromic" refers to a
multilayer film, the layers of which are substantially symmetrical.
Non-limiting examples of palindromic films are films or sheets
having the layer sequence of configurations: A/B/A or A/B/B/A or
A/B/C/B/A or A/B/C/D/C/B/A or A/B/C/B/D/B/C/B/A or
A/B/E/D/E/B/C/B/E/D/E/B/A, etc. A palindromic thermoplastic film
may be coextruded as a symmetrical cast or a blown film using
coextrusion methods generally well known in the art. An alternative
method of producing palindromic films is by the use of blown
coextrusion of non-symmetrical film or sheet structures followed by
collapsing the blown bubble around a central core layer. An
exemplary method of producing a base component may include
producing a single-bubble blown film by forcing a non-palindromic
film composition through a multi-manifold circular die head to form
a cylindrical bubble. The cylindrical bubble may be immediately
quenched, such as by a cooled water bath, solid surface, and/or
air, and collapsed onto itself and formed into a palindromic
film.
[0024] According to another exemplary embodiment, the sequence of
layers in the multilayer thermoplastic film of the base component
is non-palindromic. An example of a layer sequence configuration of
a non-palindromic film would be A/B/C or AB/C/A.
[0025] In one embodiment, the thermoformed base component may be
characterized as a palindromic film formed from a non-symmetrical
film having a generic layer sequence configuration of A/B/C which
is coextruded by blown film coextrusion techniques and collapsed
upon itself to produce a layer sequence configuration of AB/CB/A.
In this embodiment, the thermoformed base component includes a film
where layer A is an exterior layer comprising a cyclic olefin
copolymer (COC). Layer B may be an interior layer comprising at
least one of a high density polyethylene (HDPE), a blend of high
density polyethylene, a high density polyethylene nucleation
additive and optionally, a hydrocarbon resin, a bimodal high
density polyethylene having a distribution of a low molecular
weight region and a high molecular weight region, or a high density
polyethylene (HDPE) and may have a thickness of between about 38.1
.mu.m and about 190.5 .mu.m (about 1.5 mil to about 7.5 mil). Layer
C is a central core layer. The central core layer C may be any
suitable polymeric material which can be blown coextruded and
collapsed upon itself. One non-limiting example of such polymeric
materials is ethylene vinyl acetate copolymer (EVA).
[0026] In another embodiment, the thermoformed base component may
be characterized as a non-palindromic film having a layer sequence
configuration of A/B/C/B/D which is coextruded by blown film
coextrusion techniques and is not collapsed upon itself. In this
embodiment, the thermoformed base component includes a film where
layer A is an exterior layer comprising a material selected from
the group consisting of cyclic olefin copolymer (COC). Layer B may
be an interior layer comprising a high density polyethylene (HDPE),
a blend of high density polyethylene, high density polyethylene
nucleation additive and optionally, a hydrocarbon resin
(HDPE-Blend), a bimodal high density polyethylene having a
distribution of a low molecular weight region and a high molecular
weight region (HDPE-Bimodal), or a high density polyethylene and
has a thickness of between about 38.1 .mu.m to about 190.5 .mu.m
(about 1.5 mil to about 7.5 mil). Layer C is a central core layer,
and layer D is an exterior layer comprising a different material
than layer A. Layer D may include at least one of polypropylene
(PP), high impact polystyrene (HIPS), general purpose polystyrene
(GPPS), styrene block copolymer (SBC), polyethylene terephthalate
(PET), oriented polyethylene terephthalate (OPET), amorphous
polyethylene terephthalate (APET), glycol-modified polyethylene
terephthalate (PETG) biaxially oriented nylon (BON), and polylactic
acid (PLA). Core layer C may be any thermoplastic material. In one
particular embodiment, core layer C comprises ethylene vinyl
acetate copolymer (EVA).
[0027] The thermoformed base component may also include additional
film layers. For example, the base component may include additional
interior layers, such as an oxygen barrier and a moisture barrier,
disposed between the external layers and the core layer.
Additionally, the base component may include tie layers disposed
between the interior layers of the multilayer film.
[0028] The multilayer thermoplastic film of the thermoformed base
component may include any number of film layers and film layer
compositions depending upon both functional and aesthetic
requirements of the base component. It is desirable that the
multilayer thermoplastic film includes one or more film layers
which are barrier materials and substantially chemically insert
when in contact with a product. The term "barrier" refers to a
material that controls permeability of one or more elements through
a film structure including moisture, chemicals, heat, odor, and
oxygen or other gases. A barrier material may be provided by a
single film layer or multiple film layers acting individually or in
concert with each other, respectively. The phrase "substantially
chemically insert" as used herein refers to materials that
generally are not reactive with the product with which it comes
into contact with and does not leech chemical ingredients into the
product with which it comes into contact. According to an exemplary
embodiment, the base component comprises a multilayer thermoplastic
film which provides an average water vapor transmission rate of
less than about 0.500 g/m.sup.2/day or less than about 0.250
g/m.sup.2/day or less than about 150 g/m.sup.2/day or less than
about 0.131 g/m.sup.2/day or less than about 0.110 g/m.sup.2/day at
100.degree. F. (37.8.degree. C.) and 90% relative humidity and has
a thickness of about 10 mil (about 254 micron) before being
thermoformed. The aforementioned features may be achieved by a
multilayer thermoplastic film comprising at least 3, 4, 5, 7, 8, 9,
10, 11, 12, 13, or more layers.
[0029] In one embodiment as depicted in FIG. 3, thermoformed base
component 12 comprises a multilayer thermoplastic film 100
comprising a five-layer structure of a first exterior layer 101, a
first interior layer 102, a central core layer 103, a second
interior layer 104, and a second exterior layer 105. In one
embodiment, first and second exterior layers 101 and 105 comprise
the same materials. In another embodiment, first and second
exterior layers 101 and 105 comprise different materials. The first
exterior layer 101 is a product contacting layer that includes a
cyclic olefin copolymer (COC).
[0030] For example, in one embodiment, first and second exterior
layers 101 and 105 each comprise a cyclic olefin copolymer (COC).
The COC contained in the first exterior layer 101 may be the same
as the COC contained in the second exterior layer 105.
Alternatively, the COC contained in the first exterior layer 101
may be different than the COC contained in the second exterior
layer 105. First and second interior layers 102 and 104 each
comprise at least one of a high density polyethylene (HDPE), a
blend of a high density polyethylene and a high density
polyethylene nucleation additive with an optional hydrocarbon resin
(HDPE-Blend), or a bimodal high density polyethylene having a
distribution of a low molecular weight region and a high molecular
weight region (HDPE-Bimodal), and have a thickness of between about
38.1 .mu.m to about 190.5 .mu.m (about 1.5 mil to about 7.5 mil).
Core layer 103 comprises ethylene vinyl acetate copolymer (EVA).
Alternatively, the first exterior layer 101 comprises cyclic olefin
copolymer (COC) and the second exterior layer 105 comprises a
different material than first exterior layer 101 which includes at
least one of polypropylene (PP); aromatic polyesters such as, but
not limited to, polyethylene terephthalate (PET), oriented
polyethylene terephthalate (OPET), amorphous polyethylene
terephthalate (APET), glycol-modified polyethylene terephthalate
(PETG); aliphatic polyesters such as, but not limited to,
polylactic acid (PLA); polyhydroxyalkonates including but not
limited to polyhydroxypropionate, poly(3-hydroxybutyrate) (PH3B),
poly(3-hydroxyvalerate) (PH3V), poly(4-hydroxybutyrate) (PH4B),
poly(4-hydroxyvalerate) (PH4V), poly(5-hydroxyvalerate) (PH5V),
poly(6-hydroxydodecanoate) (PH6D); biaxially oriented nylon (BON);
or polystyrenes such as, but not limited to, high impact
polystyrene (HIPS), general purpose polystyrene (GPPS), and styrene
block copolymer (SBC).
[0031] As used herein, the term "cyclic olefin copolymer" refers to
copolymers having at least one norbornene structural moiety within
the repeating backbone of the polymer. Suitable COCs for use in the
present invention may have a heat deflection temperature under load
(0.45 MPa) of at least about 75.degree. C., 130.degree. C.,
150.degree. C., 170.degree. C., or more. The COCs utilized herein
may have a glass transition temperature in a range from about
50.degree. C. to about 178.degree. C. such as from about 65.degree.
C. to about 138.degree. C. Examples of commercially-available
cyclic olefin copolymers include, but are not limited to, the
TOPAS.RTM. family of resins which is supplied by Celanese
Corporation (Irving, Tex., USA). The COC containing product contact
layers are anti-scalping layers, in that they resist migration of
chemicals, such as active agents, from the product to the packaging
materials (either through direct contact with the product or
through volatiles components from the product impinging on or
migrating to the packaging material). Such migration of chemicals
from the product to packaging materials is commonly referred to as
"scalping." The COC containing product contact layers are
advantageously characterized as being anti-scalping with regard to
at least nicotine and fentanyl.
[0032] As utilized herein, a product contacting layer of a film is
considered to serve as an effective "anti-scalping layer" for
pharmacological active agents if (i) a lower amount of an active
agent migrates into the product contacting layer of the film (the
test film) than migrates into a substantially similar film having a
polyethylene (PE), such as a linear low density polyethylene
homopolymer, product contacting layer (the reference film) when a
product containing the active agent is in direct contact with the
product contacting layers of the test and reference films; or (ii)
an amount of the active agent that migrates into the product
contacting layer of the film (the test film) is not more than 15%
greater than migrates into a substantially similar film having a
Barex.RTM. product contacting layer (the reference film) when a
product containing the active agent is in direct contact with the
product contacting layers of the test and reference films.
Preferably, the product is sealed in a cavity formed, at least in
part, by the test film and the product is sealed in a cavity
formed, at least in part, by the reference film. The sealed product
can be stored under identical conditions prior to testing to
determine whether less active agent has migrated into the product
contacting layer of the test film than the reference film. A film
may still have anti-scalping properties even if it is not an
effective anti-scalping layer as defined above. For example, a film
that is not an effective anti-scalping layer for pharmacological
active agents may exhibit sufficient anti-scalping properties for
other applications.
[0033] The COCs utilized herein may be are commercially available
amorphous, transparent copolymers of ethylene with norbornene made
by polymerization with a metallocene catalyst. These commercially
available COCs reportedly have high transparency and gloss,
excellent moisture barrier and aroma barrier properties, high
stiffness, high strength, excellent biocompatibility and inertness
and are easy to extrude and thermoform. The COC materials may have
an ethylene-norbornene comonomer content of about 20 to about 40
mole % ethylene and about 30 to about 60 mole % norbornene. In some
embodiments, the COC materials described herein may include
polymeric units derived from essentially only ethylene and
norbornene comonomers.
[0034] A "product contacting layer" refers to a layer that under
typical storage conditions some portion of the product or an active
agent contained within the product will contact the layer. The
active agent may be in direct contact with the product contacting
layer or may be in indirect contact with the product contacting
layer. Indirect contact between the active agent and the product
contacting layer can occur, for example, due to volatilization of
the active agent or an active agent carrier within the package to
cause the active agent, which is not stored in direct contact with
the product contacting layer, to contact the layer. The product
contacting layer includes at least 50% by weight of COC, such as at
least 75% by weight of COC, at least 90% by weight of COC, at least
95% by weight COC, or 100% by weight COC. In the case that the
product contacting layer contains less than 50% by weight COC, the
anti-scalping properties of the product contacting layer may be
undesirably reduced.
[0035] The product contacting layer also functions as a "heat
sealing layer" or "heat sealable layer" which are used
interchangeably herein to refer to a layer which is heat sealable
i.e., capable of fusion bonding by conventional indirect heating
means which generate sufficient heat on at least one film contact
surface for conduction to the contiguous film contact surface and
formation of a bond interface therebetween without loss of the film
integrity. The bond interface between contiguous inner layers of
the produced seal preferably has sufficient physical strength to
withstand the packaging process and subsequent handling.
Advantageously, the bond interface is preferably sufficiently
thermally stable to prevent gas or liquid leakage therethrough when
exposed to above or below ambient temperatures e.g. during one or
more of the following: packaging operations, storage, handling, and
transport.
[0036] As used throughout this application, the term
"polypropylene" refers to a homopolymer or copolymer having a
propyl or C-3 linkage between monomer units. A non-limiting example
of a suitable propylene copolymer is Propylene 4170 available from
Total Petrochemicals USA, Inc. (Houston, Tex.). Other non-limiting
examples of polypropylenes include Polypropylene 3287WZ, which is
available from Total Petrochemicals USA, Inc. (Houston, Tex.); and
H02C-00 Polypropylene Homopolymer, which is available from Ineos
Olefins & Polymers USA (League City, Tex.).
[0037] As used throughout this application, the term "polyester"
refers to a homopolymer or copolymer having an ester linkage
between monomer units which may be formed, for example, by
condensation polymerization reactions between a dicarboxylic acid
and a diol. The ester linkage can be represented by the general
formula: [O--R--OC(O)--R'--C(O)].sub.n where R and R' are the same
or different alkyl (or aryl) group and may be generally formed from
the polymerization of dicarboxylic acid and diol monomers
containing both carboxylic acid and hydroxyl moieties. The
dicarboxylic acid (including the carboxylic acid moieties) may be
linear or aliphatic (e.g., lactic acid, oxalic acid, maleic acid,
succinic acid, glutaric acid, adipic acid, pimelic acid, suberic
acid, azelaic acid, sebacic acid, and the like) or may be aromatic
or alkyl substituted aromatic (e.g., various isomers of phthalic
acid, such as paraphthalic acid (or terephthalic acid), isophthalic
acid and naphthalic acid). Specific examples of a useful diol
include but are not limited to ethylene glycol, propylene glycol,
trimethylene glycol, 1,4-butane diol, neopentyl glycol, cyclohexane
diol and the like. Polyesters may include a homopolymer or
copolymer of alkyl-aromatic esters including but not limited to
polyethylene terephthalate (PET), amorphous polyethylene
terephthalate (APET), crystalline polyethylene terephthalate
(CPET), glycol-modified polyethylene terephthalate (PETG) and
polybutylene terephthalate; a copolymer of terephthalate and
isophthalate including but not limited to polyethylene
terephthalate/isophthalate copolymer. Aliphatic esters include but
not limited to polylactic acid (PLA); polyhydroxyalkonates
including but not limited to polyhydroxypropionate,
poly(3-hydroxybutyrate) (PH3B), poly(3-hydroxyvalerate) (PH3V),
poly(4-hydroxybutyrate) (PH4B), poly(4-hydroxyvalerate) (PH4V),
poly(5-hydroxyvalerate) (PH5V), poly(6-hydroxydodecanoate) (PH6D);
and blends of any of these materials. A non-limiting example of
PETG is Eastar.TM. Copolyester 6763, which is also available from
Eastman Chemical Company (Kingsport, Tenn.).
[0038] As used herein, the term "polylactic acid" is used
synonymously throughout this disclosure to describe homopolymers or
copolymers having an ester linkage between monomer units and can be
represented by the general formula: [--OCH(R)C(O)--].sub.n where
R.dbd.CH.sub.3. Polylactic acid may be fabricated by polymerizing
lactic acid, which is mostly produced from by carbohydrate
fermentation of corn. Polylactic acid may be also produced by
polymerization of lactide which obtained by condensation of two
lactic acid molecules. Polylactic acid has a glass transition
temperature ranging from 50.degree. C. to 80.degree. C., while the
melting temperature ranges from 130.degree. C. to 180.degree. C.
Polylactic acid is known by those skilled in the art and fully
disclosed in U.S. Pat. Nos. 5,698,322; 5,142,023; 5,760,144;
5,593,778; 5,807,973; and 5,010,145, the entire disclosure of each
of which is hereby incorporated by reference. Examples of
commercially available polylactic acid are sold under the trademark
NatureWorks.TM. PLA Polymer in grades 4031-D, 4032-D, and 4041-D
from Cargill Dow LLC, Minneapolis, Minn., U.S.A.
[0039] As used throughout this application, the term "polystyrene"
or "PS" refers to a homopolymer or copolymer having at least one
styrene repeating linkage (such as benzene (i.e., C.sub.6H.sub.5)
having an ethylene substituent) within the repeating backbone of
the polymer. The styrene linkage can be represented by the general
formula: [CH.sub.2--CH.sub.2 (C.sub.6H.sub.5)].sub.n. Polystyrene
may be formed by any method known to those skilled in the art.
Examples of styrenic polymers include but are not limited to high
impact polystyrene (HIPS), general purpose polystyrene (GPPS) and
styrene block copolymer (SBC). HIPS is sometimes called
rubber-modified polystyrene and is normally produced by
copolymerization of styrene and a synthetic rubber. (See Wagner, et
al., "Polystyrene," The Wiley Encyclopedia of Packaging Technology,
Second Edition, 1997, pp. 768-771 (John Wiley & Sons, Inc., New
York, N.Y.), which is incorporated in its entirety in this
application by this reference.) Examples of HIPS include but are
not limited to Impact Polystyrene 825E and Impact Polystyrene 945E,
both of which are available from Total Petrochemicals USA, Inc;
EB6025 Rubber Modified High Impact Polystyrene, which is available
from Chevron Phillips Company (The Woodlands, Tex.); and 6210 High
Impact Polystyrene, which is available from Ineos Nova LLC
(Channahon, Ill.). GPPS is often called crystal polystyrene, as a
reference to the clarity of the resin. Examples of GPPS include but
are not limited to Crystal Polystyrene 524B and Crystal Polystyrene
525B, both of which are available from Total Petrochemicals USA,
Inc. Styrene block copolymers (SBC) include styrene butadiene
copolymers (SB). The styrene-butadiene copolymers that are suitable
for packaging applications are those resinous block copolymers that
typically contain a greater proportion of styrene than butadiene
and that are predominantly polymodal with respect to molecular
weight distribution. (See Hartsock, "Styrene-Butadiene Copolymers,"
The Wiley Encyclopedia of Packaging Technology, Second Edition,
1997, pp. 863-864 (John Wiley & Sons, Inc., New York, N.Y.),
which is incorporated in its entirety in this application by this
reference.) A non-limiting example of SB is DK13 K-Resin.RTM.
Styrene-Butadiene Copolymer, which is available from Chevron
Phillips Chemical Company (The Woodlands, Tex.).
[0040] As used herein, the phrase "high density polyethylene" or
"HDPE" refers to homopolymers of ethylene that have densities of
about 0.960 g/cm.sup.3 to about 0.970 g/cm.sup.3 as well as
copolymers of ethylene and an alpha-olefin (such as 1-butene or
1-hexene) that have densities of about 0.940 g/cm.sup.3 to about
0.958 g/cm.sup.3. In contrast, a low density polyethylene (LDPE)
generally has a density of about 0.915 g/cm.sup.3 to about 0.930
g/cm.sup.3. HDPE is inclusive of polymers made with Ziegler or
Phillips type catalysts and polymers made with single-site
metallocene catalysts. A non-limiting example of high density
polyethylene includes Alathon.RTM. M6020 from Equistar Chemicals LP
(Houston, Tex.). Other specific non-limiting examples of HDPE
include Alathon.RTM. M6020 available from Equistar Chemicals LP
(Houston, Tex.); Alathon.RTM. L5885 available from Equistar
Chemicals LP (Houston, Tex.); ExxonMobil.TM. HDPE HD 7925.30
available from ExxonMobil Chemical Company (Houston, Tex.); and
ExxonMobil.TM. HDPE HD 7845.30 available from ExxonMobil Chemical
Company (Houston, Tex.).
[0041] In one particular embodiment, first and second exterior
layers 101 and 105 each independently include at least 50%, 75%,
90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or more cyclic
olefin copolymer (COC) by weight relative to the total weight of
the layer, and first and second interior layers 102 and 104 each
comprise high density polyethylene (HDPE).
[0042] In another preferred embodiment, the first exterior layer
101 includes at least 50%, 75%, 90%, 91%, 92%, 93%, 94%, 95%, 96%,
97%, 98%, 99% or more cyclic olefin copolymer (COC) by weight
relative to the total weight of the layer, the second exterior
layer 105 comprises at least 50%, 60%, 70%, 80%, 90%, 95% or more
of another material by weight relative to the total weight of the
layer. The another material of the second exterior layer 105 may be
at least one of polypropylene (PP), high impact polystyrene (HIPS),
general purpose polystyrene (GPPS), styrene block copolymer (SBC),
polyethylene terephthalate (PET), oriented polyethylene
terephthalate (OPET), amorphous polyethylene terephthalate (APET),
glycol-modified polyethylene terephthalate (PETG), or polylactic
acid (PLA). The first and second interior layers 102 and 104 may
each include high density polyethylene (HDPE) and have a thickness
of at least 20%, 25%, 30%, 35% or more of the total thickness of
the multilayer thermoplastic film 100. The first and second
interior layers 102 and 104 may each have a thickness of between
about 38.1 .mu.m and about 190.5 .mu.m (about 1.5 mil to about 7.5
mil).
[0043] In another particular embodiment, the first and second
interior layers 102 and 104 each include a blend of a high density
polyethylene and a high density polyethylene nucleation additive
(HDPE-Blend). As used herein, the phrase "nucleation additive"
means a material that increases high density polyethylene
crystallinity as a result of its incorporation into HDPE. Such
nucleation additives typically provide better control over
crystallization rates. Examples of nucleation additives include
minerals such as chalk, talc, clay, kaolin, silicates and the like,
and organic agents such as salts of aliphatic or aromatic
carboxylic acids, aromatic salts, metallic salts of aromatic
phosphorous compounds, quinaridones, and aromatic amides. Further
examples include zinc glycerolate, calcium glycerolate, calcium
hexahydrophthalate, zinc hexahydrophthalate, salts and the like,
and mixtures thereof. In one embodiment, the nucleation additive
comprises calcium hexahydrophthalate. The nucleation additive may
be present in each interior layer of HDPE in an amount from about
0.2% to about 3.5% by weight relative to the total weight of the
layer.
[0044] In another embodiment, the first and second interior layers
102 and 104 each include a blend of a high density polyethylene, a
high density polyethylene nucleation additive and/or a hydrocarbon
resin (HDPE-Blend). The hydrocarbon resin may be present in the
first and second interior layers 102 and 104 in an amount from
about 3% to about 16% by weight relative to the total weight of the
layer. As used herein, the phrase "hydrocarbon resin" refers to a
product produced by polymerization from coal tar, petroleum, and
turpentine feed stocks, as defined by ISO Standard 472,
"Plastics--Vocabulary" incorporated by reference herein to the
extent that it discloses hydrocarbon resins. A hydrocarbon resin
may comprise any of those hydrocarbon resins disclosed in U.S. Pat.
No. 6,432,496, issued Aug. 13, 2002, or in U.S. Patent Application
2008/0286547, published Nov. 20, 2008, both of which are
incorporated in their entireties in this application by this
reference. More specifically, as a non-limiting example, the
hydrocarbon resin may include petroleum resins, terpene resins,
styrene resins, cyclopentadiene resins, saturated alicyclic resins,
or mixtures thereof. Additionally, as a non-limiting example, the
hydrocarbon resin may include a hydrocarbon resin derived from the
polymerization of olefin feeds rich in dicyclopentadiene (DCPD),
from the polymerization of olefin feeds produced in the petroleum
cracking process (such as crude C9 feed streams), from the
polymerization of pure monomers (such as styrene,
.alpha.-methylstyrene, 4-methylstyrene, vinyltoluene, similar pure
monomer feedstocks, or any combination thereof), from the
polymerization of terpene olefins (such as .alpha.-pinene,
.beta.-pinene, or d-limonene) or from a combination thereof. The
hydrocarbon resin may be fully or partially hydrogenated. Specific
examples of hydrocarbon resins include but are not limited to
Plastolyn.RTM. R1140 Hydrocarbon Resin available from Eastman
Chemical Company (Kingsport, Tenn.), Regalite.RTM. T1140 available
from Eastman Chemical Company (Kingsport, Tenn.), Arkon.RTM. P-140
available from Arakawa Chemical Industries, Limited (Osaka, Japan)
and Piccolyte.RTM. 5135 Polyterpene Resins available from Hercules
Incorporated (Wilmington, Del.).
[0045] In another embodiment, the first and second interior layers
102 and 104 each include high density polyethylene having a
bi-modal molecular weight distribution having a low molecular
weight region and a high molecular weight region
(HDPE-Bimodal).
[0046] The interior layers may be barrier layers. The interior
layers may provide gas barrier functionality and moisture barrier
functionality, and this functionality may be provided by a single
barrier layer or by separate barrier layers.
[0047] A gas barrier layer may be an oxygen barrier layer. An
oxygen barrier is preferably selected to provide a sufficiently
limited oxygen permeability such that the packaged product is
protected from undesirable deterioration or oxidative processes.
For example, a film may comprise an oxygen barrier having an oxygen
permeability that is low enough to prevent oxidation of oxygen
sensitive products and substances to be packaged in the film--e.g.,
oxygen sensitive articles such as transdermal patches (such as
nicotine or fentanyl patches). Preferably an oxygen barrier
provides an oxygen permeability of less than or equal to 10
cm.sup.3/100 inches.sup.2/24 hours at 1 atmosphere and 23.degree.
C., such as less than 0.016 cm.sup.3/m.sup.2 per 24 hours at 1
atmosphere. To protect oxygen sensitive articles from deterioration
from oxygen contact over time the oxygen barriers of the base
components according to the present invention may provide an oxygen
transmission rate (O.sub.2TR) of less than 1, preferably less than
0.1, more preferably less than 0.01, and most preferably less than
0.001 g/100 inches.sup.2 at 24 hours at Room Temperature (RT)
(-23.degree. C.) and 1 atmosphere, such as <0.001 g/m.sup.2 at
24 hours at RT and 1 atmosphere.
[0048] A moisture barrier may provide a sufficiently limited
moisture permeability such that the packaged product is protected
from undesirable deterioration. For example, a moisture barrier may
have a moisture permeability that is low enough to prevent
deleterious effects upon packaged products, such as transdermal
drug patches or other moisture sensitive products. A preferred film
according to various embodiments will have a water or moisture
transmission rate (WVTR) of less than 0.01 g/100 inches.sup.2 per
24 hours at Room Temperature (RT) (23.degree. C.) and 1 atmosphere.
In some embodiments, a film has a WVTR of less than 0.01 g/100
inches.sup.2 per 24 hours at RT and 1 atmosphere, such as less than
0.001 g/100 inches.sup.2 per 24 hours at RT and 1 atmosphere.
[0049] A barrier layer as described herein may include any suitable
material. An oxygen barrier layer may include EVOH, polyvinylidene
chloride, polyamide, polyester, polyalkylene carbonate,
polyacrylonitrile, nanocomposite, a metallized film such as
aluminum vapor deposited on a polyolefin, etc., as known to those
of skill in the art. Suitable moisture barrier layers include
aluminum foil, PVDC, or polyolefins such as LDPE or LLDPE. It is
desirable that the thickness of the barrier layer be selected to
provide the desired combination of the performance properties
sought e.g. with respect to oxygen permeability, and delamination
resistance, and water barrier properties. Suitable thicknesses of
the barrier layer are less than 15%, e.g. from 3 to 13% of the
total film thickness and preferably less than about 10% of the
total thickness of the multilayer film. Greater thicknesses may be
employed. For example, the thickness of an oxygen barrier layer may
advantageously be less than about 0.45 mil (about 10.16 microns)
and greater than about 0.05 mil (about 1.27 microns), including
thicknesses of 0.10 mil, 0.20 mil, 0.25 mil, 0.30 mil, 0.40 mil, or
0.45 mil.
[0050] In one exemplary embodiment, the central core layer 103
comprises an ethylene vinyl acetate copolymer (EVA) and more
preferably, an ethylene vinyl acetate copolymer (EVA) having a 12%
by weight vinyl acetate content. Non-limiting examples of EVA
include Escorene.TM. Ultra LD 705.MJ available from ExxonMobil
Chemical Company (Houston, Tex.), Escorene.TM. Ultra LD 768.MJ
available from ExxonMobil Chemical Company (Houston, Tex.) and
Ateva.RTM. 2861AU available from Celanese Corporation (Edmonton,
Alberta, Canada).
[0051] Exemplary five-layer embodiments of the base component
described above may include, but are not limited to the following
layer sequences and general layer compositions:
COC/HDPE/EVA/HDPE/COC; COC/HDPE-Blend/EVA/HDPE-Blend/COC;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/COC; COC/HDPE/EVA/HDPE/PP;
COC/HDPE-Blend/EVA/HDPE-Blend/PP;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/PP; COC/HDPE/EVA/HDPE/PETG;
COC/HDPE-Blend/EVA/HDPE-Blend/PETG;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/PETG; COC/HDPE/EVA/HDPE/APET;
COC/HDPE-Blend/EVA/H DPE-Blend/APET;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/APET; COC/HDPE/EVA/HDPE/PET;
COC/HDPE-Blend/EVA/HDPE-Blend/PET;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/PET; COC/HDPE/EVA/HDPE/OPET;
COC/HDPE-Blend/EVA/HDPE-Blend/OPET;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/OPET; COC/HDPE/EVA/HDPE/PLA;
COC/HDPE-Blend/EVA/HDPE-Blend/PLA;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/PLA; COC/HDPE/EVA/HDPE/HIPS;
COC/HDPE-Blend/EVA/HDPE-Blend/HIPS;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/HIPS; COC/HDPE/EVA/HDPE/GPPS;
COC/HDPE-Blend/EVA/HDPE-Blend/GPPS;
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/GPPS; COC/HDPE/EVA/HDPE/SBC;
COC/HDPE-Blend/EVA/HDPE-Blend/SBC; and
COC/HDPE-Bimodal/EVA/HDPE-Bimodal/SBC.
[0052] The above examples may further include a tie layer
comprising a tie layer material, such as between a high density
polyethylene layer and the second exterior layer. The term "tie
layer," or "adhesive layer," refers to a layer or material placed
on one or more layers to promote the adhesion of that layer to
another surface. Preferably, adhesive layers are positioned between
two layers of a multilayer film to maintain the two layers in
position relative to each other and prevent undesirable
delamination. In some embodiments a peelable tie layer may be used
which is designed to have either cohesive failure or delamination
from one or both adjacent layers upon application of a suitable
manual force to provide an opening feature for a package made from
the film. Unless otherwise indicated, an adhesive layer can have
any suitable composition that provides a desired level of adhesion
with the one or more surfaces in contact with the adhesive layer
material. Optionally, an adhesive layer placed between a first
layer and a second layer in a multilayer film may comprise
components of both the first layer and the second layer to promote
simultaneous adhesion of the adhesive layer to both the first layer
and the second layer to opposite sides of the adhesive layer. Tie
layer materials may include, but are not limited to, unmodified
polyolefins such as polyethylenes and ethylene vinyl acetate
copolymers, unmodified ester copolymers such as ethylene acrylate
copolymers and ethylene methacrylate copolymers, unmodified
ethylene acid copolymers such as ethylene acrylic acid copolymers,
and blends thereof. Tie layer materials may also include modified
polyolefins including, but not limited to anhydride modified
polyethylenes, anhydride modified ethylene vinyl acetate
copolymers, modified ester copolymers such as anhydride modified
ethylene acrylate copolymers, modified ethylene acid copolymers
such as anhydride modified ethylene acrylic acid copolymers, and
blends thereof. Tie layer materials may further include a blend of
an unmodified polyolefin, unmodified ester copolymer, or unmodified
ethylene acid copolymer and a modified polyolefin, modified ester
copolymer, or modified ethylene acid copolymer. In a preferred
embodiment, a tie layer may be present between a layer comprising
high density polyethylene and the second exterior layer comprising
polypropylene (PP), high impact polystyrene (HIPS), general purpose
polystyrene (GPPS), styrene block copolymer (SBC), polyethylene
terephthalate (PET), oriented polyethylene terephthalate (OPET),
amorphous polyethylene terephthalate (APET), glycol-modified
polyethylene terephthalate (PETG) or polylactic acid (PLA).
[0053] In another exemplary embodiment as depicted in FIG. 4,
thermoformed base component 12 comprises a multilayer palindromic
thermoplastic film 200 which comprises a thirteen-layer symmetrical
structure of a first exterior layer 201, a first interior layer
202, a second interior layer 203, a third interior layer 204, a
fourth interior layer 205, a fifth interior layer 206, a sixth
interior layer 207, a central core layer 208, a seventh interior
layer 209, an eighth interior layer 210, a ninth interior layer
211, a tenth interior layer 212, an eleventh interior layer 213,
and a second exterior layer 214. In this embodiment, film 200
comprises two exterior layers each comprising cyclic olefin
copolymer (COC), two discrete interior layers each comprising
ethylene vinyl alcohol copolymer (EVOH), and four discrete interior
layers each comprising high density polyethylene (HDPE). This
thirteen-layer embodiment has the following layer sequence and
general layer composition:
COC/HDPE/tie/EVOH/tie/HDPE/EVA/HDPE/tie/EVOH/tie/HDPE/COC. The HPDE
containing layers may include a HDPE nucleation additive and a
hydrocarbon resin, and provide moisture barrier functionality. The
EVOH containing layers provide oxygen barrier functionality.
[0054] The total thickness of multilayer thermoplastic films of the
thermoformed base component 12 of the present invention is
generally from about 12.7 .mu.m (0.5 mil) to about 508 .mu.m (20
mil), such as from about 50.8 .mu.m (2 mil) to about 254 .mu.m (10
mil), or from about 76.2 .mu.m (3 mil) to about 203.2 .mu.m (8
mil).
Lidding Component
[0055] The packages of the present invention also include a lidding
component which includes a cyclic olefin copolymer product
contacting layer that is heat-sealable to the product contacting
layer of the base component.
[0056] One exemplary embodiment of a lidding component 11 is
depicted in FIG. 5. In this embodiment, lidding component 11
comprises a laminate 300 having a first exterior layer 301, an
interior layer 302 and a second exterior layer 303. The second
exterior layer 303 is a product contacting layer that includes at
least 50% by weight of a cyclic olefin copolymer relative to the
total weight of the layer, the first exterior layer 301 comprises
paper, biaxially oriented nylon, biaxially oriented polypropylene,
or oriented polyethylene terephthalate, and interior layer 302
comprises a metal foil such as aluminum. A tie or adhesive layer
disposed between and bonding exterior layer 301 and interior layer
302 together may also be provided.
[0057] The second exterior layer 303 may include at least 50%, 75%,
90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or more cyclic
olefin copolymer (COC) by weight relative to the total weight of
the layer. In one embodiment, the second exterior layer may consist
of a cyclic olefin copolymer. The COC contained in the second
exterior layer 303 may be any of those described above. The COC
contained in the lidding component may be the same as the COC
contained in the base component. Alternatively, the COC contained
in the lidding component may be different than the COC contained in
the base component.
[0058] The exterior layer may be any appropriate material. For
example, the exterior layer may include paper, biaxially oriented
nylon, biaxially oriented polypropylene, or oriented polyethylene
terephthalate. The exterior layer may serve to protect the lidding
component from damage and/or to provide additional strength to the
lidding component.
[0059] The interior layer may be any appropriate metal foil. For
example, the interior layer may be an aluminum foil. The metal foil
may have a thickness of on the order of about 25.4 .mu.m (about 1
mil). The foil serves as a barrier layer. The functions of the
interior layer and the first exterior layer may be combined in a
single layer, such as in a lidding component that includes only a
barrier layer and a product contacting layer.
[0060] The lidding component may be produced using an extrusion
coating apparatus and methods which are well known to those skilled
in the art. The extrusion coating apparatus may include a
multi-manifold flat die head through which a two-layer film
composition may be forced and extrusion coated onto the shiny
surface of a metallic foil. The metallic foil may be pre-treated
prior to extrusion coating by printing a primer coat onto the matte
surface of the foil. An exterior layer, such as paper or oriented
polyethylene terephthalate, may be attached to the foil before or
after the extrusion coating process.
[0061] In another exemplary embodiment as depicted in FIG. 6,
lidding component 11 includes a multilayer film 500 which has a
four-layer structure of a first exterior layer 501, a first
interior layer 502, a second interior layer 503, and a second
exterior layer 504. In this embodiment, first exterior layer 501
includes paper or oriented polyethylene terephthalate. The first
interior layer 502 includes a polyethylene extrudate or adhesive,
and the second interior layer 503 includes a metal foil. The second
exterior layer 504 is a COC containing product contact layer of the
type described above. This four-layer embodiment of the lidding
component has the following layer sequence and general layer
composition: COC/PE/foil/COC. An additional tie or adhesive layer
may optionally be present between the second interior layer 503 and
the second exterior layer 504.
Package
[0062] The packages as described herein can be manufactured using
methods known in the art. Generally, the cavities are thermoformed
from the base components of the present invention in-line just
prior to filling the cavities with a product to be packaged. The
thermoformed cavities may have any appropriate geometry, and are
not limited to the specific configuration illustrated in FIG. 1
(e.g., the package may have a greater or lesser number of
compartments, the compartments may have different sizes and/or
shapes, etc.). The lidding component is then unwound from a roll
and brought into contact with the formed and filled base component
such that the cyclic olefin copolymer product contacting layer of
the lidding component contacts the cyclic olefin copolymer product
contacting layer of the base component. The lidding and base
components are heat sealed, typically using a heated platen. Some
areas of the package may not be sealed to provide a starting point
for peeling off the lidding component prior to removing the
product. If the lidding component is not pre-printed, printing is
generally done just before heat sealing. After heat-sealing, the
individual cavities may be perforated using methods known is the
art so that they can removed at point of use.
[0063] The packages as described herein may alternatively include a
base component in the form of a tray or a container. The tray or
container base portions may be formed by any appropriate process,
and may have any appropriate geometry. For example, a cold forming
process may be utilized to form a container from a base component,
with the container being subsequently sealed to the lidding
component to form a complete container and lid package.
[0064] The seal between the lidding component and the base
component has a seal strength of at least 800 grams force per inch,
such as at least about 1,000 grams force per inch, at least about
1,200 grams force per inch, or more. The seal produced between the
COC-containing product contacting layers of the base component and
the lidding component is significantly stronger than that of a
COC-containing layer heat sealed to a polyvinylchloride (PVC) layer
or polyacrylate layer. For example, layers that contain at least
50% by weight COC may produce seal peel strengths of only about 200
gf when heat sealed with polyvinylchloride (PVC) layers or
polyacrylate layers, and such a seal strength may be insufficient
for some package applications. The sealing of the lidding component
to the base component produces a cavity where all of the surfaces
exposed to the product are formed by the cyclic olefin copolymer
product contacting layers of the lidding component or the base
component. In this manner, the packages disclosed herein provide
cavities in which every surface exposed to the product is formed of
an anti-scalping material, while also providing the desired seal
strength. The strength of the seal may be influenced by the design
of the package, such as the geometry, and the product
requirements.
[0065] The packages described herein may be utilized as packaging
for nicotine containing products. Examples of nicotine containing
products include nicotine cartridges for electronic cigarettes,
nicotine gum, and nicotine transdermal patches. The cyclic olefin
copolymer product contacting layers of the lidding component and
the base component resist the uptake of nicotine, enhancing the
shelf life and efficiency of the package. The packages may also be
utilized as packaging for other products, such as pharmaceuticals
or medications. A pharmaceutical product for packaging in a package
described herein can include any suitable pharmaceutical active
agent. In some embodiments, the pharmaceutical active agent is
selected from the group consisting of fentanyl, nicotine,
lidocaine, estradiol, clonidine, ethinyl estradiol, oxybutynin,
buprenorphine, granisitron, methylphenidate, and scopolamine. In
some embodiments, one or more of the listed pharmaceutical active
agents are included in a pharmaceutical product, such as a
transdermal patch.
Non-Limiting Examples
[0066] Blister packages with COC-containing product contacting
layers of the type described herein were tested to determine the
degree of nicotine uptake in the packaging. The product contacting
layers were formed from a commercially available CXB.TM. sealant
layer structure on a SKYBLUE.TM. blister packaging film, the
product contacting layers were 100% by weight COC. A blister
package with product contacting layers of
polychlorotrifluoroethylene (PCTFE) and polyvinylchloride (PVC) was
utilized as a control. The same amount of nicotine was placed in
each blister package, and the amount of nicotine uptake in the test
blister packaging materials, after washing out the nicotine from
the blister package, was measured after 1 week, 2 weeks, and 4
weeks of elapsed time.
[0067] As shown in Table 1, the blister packages with
COC-containing product contacting layers exhibited significantly
less uptake of nicotine than the control blister packages with PVC
product contacting layers. Thus, the blister packages with
COC-containing product contacting layers of the present invention
exhibited greater resistance to nicotine scalping than other common
blister packages, such as those with PCTFE and PVC product
contacting layers.
TABLE-US-00001 TABLE 1 Nicotine Uptake (mg) Blister Package Week 1
Week 2 Week 4 PCTFE/PVC 9.11 16.74 17.13 COC (SKYBLUE .TM. 0.71
0.62 1.00 CXB .TM. film)
[0068] As used herein, singular forms "a," "an" and "the" include
plural referents unless the context clearly dictates otherwise.
Thus, for example, reference to a "structured bottom surface"
includes examples having two or more such "structured bottom
surfaces" unless the context clearly indicates otherwise.
[0069] As used herein, the term "or" is generally employed in its
sense including "and/or" unless the content clearly dictates
otherwise. The term "and/or" means one or all of the listed
elements or a combination of any two or more of the listed
elements. The use of "and/or" in certain instances herein does not
imply that the use of "or" in other instances does not mean
"and/or".
[0070] As used herein, "have", "has", "having", "include",
"includes", "including", "comprise", "comprises", "comprising" or
the like are used in their open ended inclusive sense, and
generally mean "include, but not limited to", "includes, but not
limited to", or "including, but not limited to".
[0071] "Optional" or "optionally" means that the subsequently
described event, circumstance, or component, can or cannot occur,
and that the description includes instances where the event,
circumstance, or component, occurs and instances where it does
not.
[0072] The words "preferred" and "preferably" refer to embodiments
of the disclosure that may afford certain benefits, under certain
circumstances. However, other embodiments may also be preferred,
under the same or other circumstances. Furthermore, the recitation
of one or more preferred embodiments does not imply that other
embodiments are not useful, and is not intended to exclude other
embodiments from the scope of the inventive technology.
[0073] For purposes of the present disclosure, recitations of
numerical ranges by endpoints include all numbers subsumed within
that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5,
etc.). Where a range of values is "greater than", "less than", etc.
a particular value, that value is included within the range.
[0074] Any direction referred to herein, such as "top," "bottom,"
"left," "right," "upper," "lower," "above," below," and other
directions and orientations are described herein for clarity in
reference to the figures and are not to be limiting of an actual
device or system or use of the device or system. Many of the
devices, articles or systems described herein may be used in a
number of directions and orientations.
[0075] Unless otherwise expressly stated, it is in no way intended
that any method set forth herein be construed as requiring that its
steps be performed in a specific order. Accordingly, where a method
claim does not actually recite an order to be followed by its steps
or it is not otherwise specifically stated in the claims or
descriptions that the steps are to be limited to a specific order,
it is no way intended that any particular order be inferred. Any
recited single or multiple feature or aspect in any one claim can
be combined or permuted with any other recited feature or aspect in
any other claim or claims.
[0076] It is also noted that recitations herein refer to a
component being "configured" or "adapted to" function in a
particular way. In this respect, such a component is "configured"
or "adapted to" embody a particular property, or function in a
particular manner, where such recitations are structural
recitations as opposed to recitations of intended use. More
specifically, the references herein to the manner in which a
component is "configured" or "adapted to" denotes an existing
physical condition of the component and, as such, is to be taken as
a definite recitation of the structural characteristics of the
component.
[0077] While various features, elements or steps of particular
embodiments may be disclosed using the transitional phrase
"comprising," it is to be understood that alternative embodiments,
including those that may be described using the transitional
phrases "consisting" or "consisting essentially of," are
implied.
[0078] In the foregoing description, it will be readily apparent to
one skilled in the art that varying modifications may be made to
the present disclosure without departing from the scope and spirit
of the disclosure. Since modifications, combinations,
sub-combinations and variations of the disclosed embodiments
incorporating the spirit and substance of the inventive technology
may occur to persons skilled in the art, the inventive technology
should be construed to include everything within the scope of the
appended claims and their equivalents. The embodiments
illustratively described herein suitably may be practiced in the
absence of any element or elements, limitation or limitations,
which is not specifically disclosed herein. The terms and
expressions which have been employed are used as terms of
description and not of limitation, and there is no intention that
in the use of such terms and expressions of excluding any
equivalents of the features shown and described or portions
thereof, but it is recognized that various modifications are
possible within the scope of the invention. Thus, it should be
understood that although the present invention has been illustrated
by specific embodiments and optional features, modification and/or
variation of the concepts herein disclosed may be resorted to by
those skilled in the art, and that such modifications and
variations are considered to be within the scope of this
invention.
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